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Melt Shop “Confined Spaces”
Furnace Spill Pits Furnaces Vacuum Chambers ________________________________________________ Hydraulic System Safety The furnace hydraulic system provides motive power to perform a number of functions including opening/closing the furnace cover, tilting the furnace and pushing out the lining. General cleanliness at the hydraulic connections is critical. There is a hazard wherever heat, molten metal or flame is near hydraulic equipment. If a line or fitting ruptures, it can send a combustible spray of oil into the heat source causing injury or death. Therefore, the hydraulic system must be inspected daily and any leaking components repaired or replaced. Also, fire-resistant fluids must be used with induction furnace hydraulic systems to minimize the danger of fire. ________________________________________________ VITON Seal Safety Advisory
Operators and maintenance staff working with Inductotherm equipment must take careful note of an urgent safety hazard associated with oil seals and “O” rings made of a substance called VITON. VITON seals are used in Inductotherm equipment and we want you to be aware of a potential problem which has been brought to our attention. While safe under designed operating conditions, VITON has been found to decompose into dangerous hydrofluoric acid if exposed to high temperatures. When inspecting equipment which has been exposed to a high temperature, check if any gaskets, seals or “O” rings have suffered from decomposition. These will appear as a charred or black sticky mess. You must not, under any circumstances, touch either the seal or the equipment until a substantial cooling period has been allowed and the equipment has been decontaminated. Disposable, heavy-duty plastic gloves approved to withstand contact with hydrofluoric acid, safety glasses and a face shield must be worn and the affected area must be cleaned using wire wool and a detergent solution. The gloves must be safely discarded after use. ________________________________________________ Do Not Use “Substitute/Unauthorized” Parts
Maintain your melting system’s high level of quality, reliability, safety and performance by using only recommended and authorized OEM replacement parts. Failure to comply will void equipment warranty, can cause equipment malfunction, resulting in equipment and/or property damage including injury risk to personnel. ________________________________________________ Furnace Arcing
The sparking and arcing of the charge materials in the furnace are characteristic of induction melting and not particularly hazardous. Induction furnaces melt metal by creating a flow of heat-generating electric current within the charge materials. Although rare, a fault may develop between the coil and the furnace structure, generally resulting in coil damage and power failure. It is typically caused by loose metallic chips that work their way between the coil and furnace structure, underscoring the importance of good foundry housekeeping practices. Furnace controls also can fail due to poor foundry housekeeping practices.
________________________________________________ Mechanical Component Inspection
The following components must be inspected during each furnace reline or every two years, whichever comes first. Some components may require more frequent inspections and these items are addressed in the specific equipment manuals. Under no circumstances should the following inspections be performed if the equipment contains molten metal. Structure & Welds - The structure of the furnace and ancillary equipment such as conveyors, charge buckets, lining pushout mechanisms, etc., must be inspected for any signs of damage. This includes deformations, cracking, excessive corrosion, and damage from excessive heating. All welds must be visually inspected for signs of failure. The equipment must not be used if any of the structural components or welds are damaged. Hardware - All fasteners must be checked for tightness according to torque specifications outlined in the equipment manuals. The fasteners must also be inspected for any signs of failure, including excessive corrosion. Replace all fasteners and washers showing any signs of failure, including excessive corrosion, before restarting the equipment. Fasteners must only be replaced with fasteners of an equivalent grade and material. Hydraulics & Pneumatics - The hydraulic and pneumatic components, including interconnecting piping, must be inspected for damage and leaks. Repair all leaks before restarting the equipment. The hydraulic and pneumatic hoses must be checked for wear, cracking, and damage. Replace all worn, cracked or damaged hoses before restarting the equipment. Leaking hydraulic fluid can create both a fire and slip hazard. Water Hoses - Water hoses must be checked for wear, cracking, and damage. Replace all worn, cracked or damaged hoses and clamps before restarting the equipment. Bearings - Bearings and pivot joints must be inspected for excessive wear. Worn bearings can result in misalignment of mating structures, resulting in binding and structural loads in excess of what the equipment was designed for. Failure to replace worn bearings in a timely fashion may result in unsafe operation and much costlier repairs due to wearing of the bearing bores. Water Cooled Power Cables - Water cooled power cables must be inspected for damage and leaks. The hose must be inspected for cracking due to age and heat related deterioration. Replace all damaged or leaking water cooled power cables before restarting the equipment. The guards or insulation used to protect personnel from the exposed lead ends must be in place and in good condition. Protective Barriers - All protective barriers such as melt operator heat shields, bus bar covers, hydraulic cylinder splash shields, etc., must be inspected on a regular basis to make sure that they have not been damaged or their function compromised in any way through use. Repair or replace as necessary. ________________________________________________ IMPORTANT: |
